1/4" is way to close
I believe the plans or instructions call for something like 3/4"?
The engine will move a lot on start up and shut down. You do not want to risk the FAB hiting the cowling. At 1/4" you will also have a very difficult time getting the cowl in place.
There should be a reasonable seal but people have reported flying without any seal at all and having no noticeable performance issues. However, you want to keep ram air out of the lower side of your plenum to keep the differential pressure up for cooling so a seal is necessary.
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Fiat G.46 -(restoration in progress, if I have enough life left in me)
RV1 - Proud Pilot.
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